Inflatable packaging system

ABSTRACT

An inflatable packaging system comprised of an inflation channel that feeds a plurality of inflatable cells prevents buckling of the inflation header as the inflatable cells inflate by relieving stress along a seal line that separates the inflation header from the inflatable cells.

REFERENCE TO CO-PENDING APPLICATIONS

[0001] This is a non-provisional of provisional patent applicationserial No. 60/332,185, filed Nov. 16, 2001 by Kevin W. Anderson et al.,which is incorporated by reference herein in its entirety. Priority ofthis prior provisional application is claimed under 35 U.S.C. §119(e).

BACKGROUND OF THE INVENTION

[0002] The present invention generally relates to inflatable packaging.In particular, the present invention relates to low profile inflatablepackaging systems with improved perimeter protection, integrity andinflatability.

[0003] Inflatable packaging systems having opposing inflatable memberssealed relative to one another to form an envelope like package areknown to provide protection for relatively flat items being shipped orotherwise transported. The known inflatable packaging systems, however,do not provide ample perimeter protection for such items. There is aneed for an inflatable envelope-like packaging system with improvedperimeter protection.

[0004] Check valves for a single inflatable member are known. Also knownare inflatable packaging systems having multiple inflatable cells. Thereis a continuing need for check valves that can be easily incorporatedinto each inflatable cell of a multiple cell packaging system to ensurethe integrity of the packaging system in the event of a leak in oneregion of the packaging.

[0005] Inflatable packaging systems having multiple cells that extendtransverse from a common inflation header are subject to inflationdifficulties. As the cells fill with inflation medium, the width of eachcell decreases. The additive effect of multiple cells inflating anddecreasing in width causes a strain on the seal separating the cellsfrom the inflation header. The result of this strain is a buckling ofthe inflation header that can inhibit or even prevent an inflationmedium from traveling to cells distant from the point of buckling. Thereis a need for an multi-cell inflatable packaging system that improvesthe flow path for an inflation medium through a header to the multiplecells.

SUMMARY OF THE INVENTION

[0006] The inflatable packaging system of the present invention hasfirst and second film layers sealed together around a perimeter of therespective layers except for a gap. The gap serves as an entrance for aninflation medium to an interior defined between the first and secondfilm layers. Communicating with the gap is an inflation channel formedby a first seal of the first and second film layers adjacent to aportion of the perimeter. The inflation channel carries an inflationmedium to a plurality of inflatable cells, each of which is incommunication with the inflation channel. The plurality of inflatablecells are formed by a plurality of spaced second seals that extend fromand are transverse to the first seal. The inflatable packaging systemcomprises means for maintaining airflow through the inflation channel asthe plurality of inflatable cells are inflated.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 is a top schematic view of an inflatable member of thepresent invention.

[0008]FIG. 2 is an exploded perspective view of the film layerorientation for the inflatable member of FIG. 1.

[0009]FIG. 2a is a cross-sectional view of the inflatable member of FIG.1 taken along line 2 a-2 a of FIG. 1.

[0010]FIG. 3 is a top schematic view of an alternative embodiment of theinflatable member of the present invention.

[0011]FIG. 4 is an exploded perspective view of the film layerorientation for the inflatable member of FIG. 3.

[0012]FIG. 4a is a cross-sectional view of the inflatable member of FIG.3 taken along line 4 a-4 a of FIG. 3.

[0013]FIG. 5 is an enlarged cutaway view of an inflatable cell of theinflatable member of the present invention with an alternative valveconfiguration.

[0014]FIG. 5a is an exploded perspective view of the film layerorientation for forming the valve of FIG. 5.

[0015]FIG. 6 is a perspective view of a packaging system formed from twoinflatable members of FIG. 1.

[0016]FIG. 7 is a cross-sectional view of the packaging system of FIG. 6taken along line 7-7 of FIG. 6.

[0017]FIG. 8 is a schematic end view of an alternative packaging systemconfiguration formed from two inflatable members of the presentinvention.

[0018]FIG. 9 is a schematic cross-sectional view of the alternativepackaging system of FIG. 8.

[0019]FIG. 10 is a cross-sectional view of the packaging system of FIG.6 with enhanced perimeter protection.

[0020]FIG. 11 is an enlarged schematic cutaway view of a segment of theinflatable member of FIG. 1 incorporating pleats in the peripheralinflatable chamber.

[0021]FIG. 12 is a partial top schematic view of an alternativemulti-cell packaging system of the present invention

[0022]FIG. 13 is a first alternative embodiment of the packaging systemof FIG. 12.

[0023]FIG. 14 is a second alternative embodiment of the packaging systemof FIG. 12.

[0024]FIGS. 15 and 16 are cross-sectional views of alternateconstructions of the packaging systems of FIGS. 12-14 utilizing a oneway valve of FIGS. 5-5 a.

[0025] While the above-identified drawing figures set forth preferredembodiments of the invention, other embodiments are also contemplated,as noted in the discussion. In all cases, this disclosure presents thepresent invention by way of representation and not limitation. It shouldbe understood that numerous other modifications and embodiments can bedevised by those skilled in the art which fall within the scope andspirit of the principles of this invention. It should be specificallynoted that the figures have not been drawn to scale as it has beennecessary to enlarge certain portions for clarity. Throughout theembodiments, like reference numerals are used for like elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Packaging system 10 of the present invention is generally shownin FIG. 1. Packaging system 10 is comprised of an inflatable member 12formed of overlaying first and second layers 14 and 16 (See FIG. 2) of aflexible polymeric material. Opposing peripheral edge surfaces of layers14 and 16 are interconnected by a perimeter heat seal 18. A smallperipheral section 20 of layers 14 and 16 is left unsealed to providefor a check valve 22, such as is commonly known in the art. Suitablecheck valves are disclosed, for example, in U.S. Pat. Nos. 4,917,646 and5,711,691.

[0027] Spaced from perimeter heat seal 18 along three sides ofinflatable member 12, a heat seal 24 interconnects layers 14 and 16 todefine a peripheral inflatable chamber 26 of inflatable member 12, withinflation valve 22 communicating with a first section 27 of inflatablechamber 26. Layers 14 and 16 are further interconnected by heat seals28, which extends between heat seal segments 24 a and 24 b, to define aseries of inflatable cells 30 of inflatable member 12 of packagingsystem 10. Each inflatable cell 30 communicates with first section 27 ofinflatable chamber 26, such as via an interruption of heat seal segment24 a.

[0028] As further shown in FIGS. 1-2 a, in one preferred embodiment,inflatable cells 30 and a second section 29 of peripheral inflatablechamber 26 include a one way valve system 32 to retain air in therespective cell and/or chamber once packaging system 10 is inflated. Oneway valve 32 is formed by connecting a third polymeric layer 34 (shownin FIGS. 2-2 a) to first layer 14 with a series of heat seals which willbe further described herein.

[0029] In one preferred embodiment, valve 32 is formed by positioningthird layer 34 between first layer 14 and second layer 16. Third layer34 has a length, defined by edges 36 and 40, that is generally equal tothat of first and second layers 14 and 16, but third layer 34 has awidth, defined by opposing end edges 42 and 44, that is less than thatof first and second layers 14 and 16. Valve 32 is formed by spacing edge36 of third layer 34 from peripheral heat seal segment 18 a. Edge 36 isthen sealed relative to first layer 14 and second layer 16 by heat sealsegment 24 a. Heat seal segment 24 a completely seals edge 36 of thirdlayer 34 to second layer 16. At intervals corresponding to eachinflatable cell 30 and second section 29 of inflatable chamber 26,however, one of the opposing surfaces of either first layer 14 or thirdlayer 34 is treated with a heat resistant material (e.g., ink or paint)along heat seal segment 24 a to prevent heat sealing at the treatedsites and thereby define air inlets 38.

[0030] Edge 40 of third layer 34 is connected to first layer 14 by aheat seal that spans inflatable cells 30 (interrupted by outlets 48 asdescribed below). Opposing end edges 42 and 44 of third layer 34 areinterconnected by heat seal to first layer 14 and second layer 16 alongthe perimeter heat seal segments 18 b and 18 c, respectively. Thirdlayer 34 is further connected to first layer 14 with a series of heatwelds 46 which are generally parallel to and spaced from heat sealsegment 24 a and edge 40 of third layer 34. One of the opposing surfacesof either third layer 34 or first layer 14 is further treated with heatresistant material to prevent welding of third layer 34 and first layer14 at discreet locations along each heat weld 46 to create aserpentine-like flow path for an inflation medium from inlets 38. Eachserpentine-like flow path terminates at an outlet 48 that communicateswith an interior of inflatable member 12. Outlets 48 are formed bytreating a portion of either first layer 14 or third layer 34 adjacentto edge 40 with a heat resistant material, as previously described.

[0031] Inflatable member 12 of packaging system 10 is inflated byapplying air through inflation valve 22. The first section 27 ofperipheral inflatable chamber 26 communicates with valve 32 via inlet38. Air flows from peripheral inflatable chamber 26 through each inlet38 and the respective serpentine flow path defined by segmented heatwelds 46 and enters each inflatable cell 30 and section 29 of peripheralinflatable chamber 26 via outlets 48. As inflatable cells 30 and section29 of peripheral inflatable chamber 26 achieve their maximum inflation,the internal pressure of inflatable cell 30 and inflatable chamber 26causes opposing surfaces of third layer 34 and first layer 14 to tightlybear against one another and thereby prevent air from escapinginflatable cell 30 and peripheral inflatable chamber 26.

[0032] As shown in FIGS. 3-4 a, in an alternative embodiment, valve 32may be formed with third layer 34 connected to an outer surface 35 offirst layer 14. In this embodiment, second layer 16 is connected tosurface 37 of first layer 14 opposite the outer surface 35 of firstlayer 14. As shown in FIGS. 3-4 a, edge 36 of third layer 34 is sealedrelative to the edge of first layer 14 along perimeter heat seal segment18 a. A heat seal further connects edges 40 and 42 of third layer 34 tofirst layer 14. Edge 44 of third layer 34 is sealed relative to firstlayer 14 with the exception of the small peripheral section 20 thatdefines an inflation medium inlet, as previously described.

[0033] Second layer 16 is dimensioned to have a length defined byperimeter heat seal segments 18 b and 18 c, and a width defined by heatseal segment 24 a and perimeter heat seal segment 18 d. The perimeteredges of second layer 16 are connected to first layer 14 by heat sealsegments 18 b, 18 c, 18 d and 24 a. Heat seal segment 24 a also connectsfirst layer 14 and third layer 34, with inlets 38 being formed bytreating a portion of either first layer 14 or third layer 34 with aheat resistant material at intervals corresponding to each cell 30 toprevent sealing of adjacent surfaces of first layer 14 and third layer34 when heat seal segment 24 a is formed. Heat welds 46, as describedrelative to FIG. 1, interconnect third layer 34 to first layer 14 toform the serpentine flow path of valve 32. Outlets 48, however, in theembodiment shown in FIG. 3, are formed by an opening through first layer14 near the end of the serpentine flow path, as shown in FIG. 4a. Aspreviously described, when inflatable cells 30 and section 29 ofperipheral inflatable chamber 26 achieve their maximum inflation, theinternal pressure of inflatable cell 30 and inflatable chamber 26 causesopposing surfaces of third layer 34 and first layer 14 to tightly bearagainst one another and thereby prevent air from escaping inflatablecell 30 and peripheral inflatable chamber 26.

[0034]FIG. 5 depicts an alternative embodiment of one way valve 32 foruse with packaging system 10. FIG. 5 is an enlarged cutaway view of oneof inflatable cells 30. As shown in FIGS. 5 and 5a, the alternativeconfiguration of valve 32 consists of a pair of film layers 15 and 17positioned between first layer 14 and second layer 16. Layers 15 and 17of valve 32 are sealed relative to one another and to first and secondlayers 14 and 16 via heat seals 28 and 24. Opposing edge surfaces oflayers 15 and 17 are treated with a heat resistant material along zone19 to prevent heat sealing and thereby define an air inlet of valve 32.Heat seals 21 further interconnect layers 15 and 17 to define a flowpath 23 in communication with inflatable cell 30. Opposing edges 25 oflayers 15 and 17 remain unsealed. Thus, air flowing through peripheralinflatable chamber 26 is allowed to enter flow path 23 of valve 32 viathe inlet defined by zone 19. Air flowing through pathway 23 entersinflatable cell 30. When inflatable cell 30 reaches maximum inflation,air pressure within inflatable cell 30 urges layers 15 and 17 tightagainst one another to prevent air from escaping through air pathway 23and thereby maintain inflatable cell 30 in an inflated state.

[0035] One-way valve 32 provides integrity to inflatable member 12 ofpackaging system 10 by ensuring that an isolated air leak in one regionof inflatable member 12 will not result in a complete catastrophicfailure of packaging system 10. Inflatable member 12 of packaging system10 may be also be used, however, without one way valve 32. Packagingsystem 10 is a simple yet elegant inflatable packaging material capableof a variety of uses. For example, breakable or fragile articles can beplaced between multiple sections of inflatable member 12. Further,sections of inflatable member 12 can be sized to line the inner walls ofa shipping box to isolate fragile contents from the outer box wall. Afurther and more novel use of inflatable member 12 will be describedherein by reference to FIGS. 6-9.

[0036]FIG. 6 is a perspective view of a particularly advantageousapplication of inflatable member 12 to form an inflatable packageprotection system 60 for shipping of low profile, fragile items. System60 is generally comprised of an upper section 62 of inflatable member 12and a lower section 64 of inflatable member 12. System 60 is formed byvertically aligning the peripheral edges of sections 62 and 64, and byinterconnecting opposing peripheral surface areas of sections 62 and 64together on three sides. Interconnected sections 62 and 64 combine toform an envelope-like inflatable container with open end 66 permittingaccess of a low profile item between sections 62 and 64. While system 60is shown in an inflated state, it is to be understood that itemsrequiring protection for shipping or storage are inserted throughopening 66 and positioned between sections 62 and 64 while system 60 isin a deflated state. Each section 62 and 64 is subsequently inflatedthrough an inflation valve, such as inflation valve 22, as previouslydescribed relative to FIG. 1. Inflation of inflatable cells 30 causesopposing inner surfaces of sections 62 and 64 to bear tightly against anarticle placed within system 60 so as to securely hold the item withinthe pocket defined between sections 62 and 64. Peripheral inflatablechambers 26 of sections 62 and 64 provide particularly suitableperimeter protection particularly when system 60 is fitted within ashipping box or container.

[0037]FIG. 7 is a sectional view of system 60 taken essentially alongline 7-7 shown in FIG. 6 and further positioned within a shippingcontainer 70. As shown in FIG. 7, section 62 of inflatable member 12 isinterconnected to section 64 of inflatable member 12 by heat weldingopposing surfaces of sections 62 and 64 together along heat seal 24(which interconnects layers 14 and 16 of inflatable member 12). Tomaintain perimeter protection in the event of an air leak in one cell 30or chamber 26, section 27 of chamber 26 of section 62 is positioned onone side of system 60, while section 27 of chamber 26 of section 64 ispositioned on the other side of system 60. Sections 62 and 64 thusinterconnected, peripheral inflatable chambers 26 of system 60 providesignificant corner and edge protection for an item while maintaining alow profile and maximizing interior pocket size. An item 78 thus securedwithin system 60 is protected on its top and bottom by inflatable cells30 and about its periphery by inflatable peripheral chambers 26. System60 thereby provides a low profile inflatable package protection systemthat cushions fragile, low profile items, such as picture frames, chinaplates, or laptop computers and spaces such items from the walls of ashipping container 70, as shown in FIG. 7.

[0038]FIG. 8 is an end view of an alternative embodiment of packagingsystem 60. The embodiment of packaging system 60 shown in FIG. 8 differsfrom that shown in FIGS. 6 and 7 in that opposing surfaces of peripheralinflatable chambers 26 of sections 62 and 64 are interconnected aboutthe periphery of inflatable member 12 adjacent to heat seal 18. Theresulting configuration of packaging system 60 thereby incorporates agreater pocket area 80 to accommodate larger items.

[0039] The particular interconnection of opposing sections 62 and 64 ismore clearly shown in FIG. 9. As shown in FIG. 9, opposing surfaces ofperipheral inflatable chamber 26 are interconnected along a zone ofadhesion generally referred to by reference numeral 82. In oneembodiment, adhesion zone 82 generally extends from heat seal 18 to adistance that generally corresponds to the radius of peripheralinflatable chamber 26 when inflatable member 12 is fully inflated. Thisin turn results in greater spacing between heat seal 24 of inflatablemember 12 forming section 62 and heat seal 24 of inflatable member 12forming section 64, which in turn results in a larger pocket 80 ofpackaging system 60. In alternative embodiments, the size of pocket 80can be adjusted by varying the location of adhesion zone 82. Locatingadhesion zone closer to heat seal 24 results in a smaller pocket 80, andconversely, locating adhesion zone 82 closer to heat seal 18 results ina larger pocket 80. Packaging system 60 formed in the manner shown inFIGS. 8 and 9 thereby is able to accommodate items of variousdimensions. Furthermore, it is possible to allow inflatable member 12 ofsection 62 to communicate with inflatable member 12 of section 64 byproviding an inflation hole 22 a (shown in dotted lines in FIG. 9)between respective sections 26 of sections 62 and 64 (and any additionalsections of inflatable member 12) along adhesion zone 82. The employmentof inflation hole 22 a permits multiple sections of inflatable member 12to be inflated by a single inflation valve 22 associated with one of theinflatable members 12.

[0040]FIG. 10 is a cross-section view of another embodiment of thepackaging system 60 in which perimeter protection is further enhanced bythe formation of secondary perimeter inflation zones 25 adjacent toperipheral inflatable chambers 26. Perimeter inflation zones 25 areformed by an additional heat seal 29 of each layer 14 and 16 which isspaced from and generally parallel with heat seal 24. Segments of layers14 and/or 16 corresponding to heat seal 29 are treated with a heatresistant material along heat seal 29 in the manner previously describedsufficient to form gaps in heat seal 29 and thereby allow the inflationmedium to fill inflatable cells 30 and perimeter inflation zones 25.Perimeter inflation zones 25 combined with peripheral inflatablechambers 26 increase the edge distance of item 78 from shippingcontainer 70 and provide enhanced cushioning for the perimeter edges offragile items.

[0041]FIG. 11 is an enlarged cutaway view of a segment of an inflatablemember 12 relative to inflatable cell 30 and that portion of peripheralinflatable chamber 26 extending transverse to inflatable cells 30. FIG.11 depicts a modification to the formation of peripheral inflatablechamber 26 to minimize buckling of inflatable chamber 26 when inflatablemember 12 is fully inflated. As cells 30 of inflatable member 12inflate, the length L of inflatable member 12 decreases. In response tothis decrease in length, inflatable chamber 26 has a tendency to buckleor crimp at one or more locations along the length L of inflatablemember 12, which can cause inflatable member 12 to curl along itslength. To compensate for this buckling or crimping effect of inflatablechamber 26, one or more pleats 90 are formed by a V-shaped heat weld ofthe opposing surfaces of first layer 14 and second layer 16 along heatseal segments 18 a and 18 d. As shown in FIG. 11, pleats 90 extend fromheat seal 18 to a point 92 that is sufficiently spaced from heat seal 24to allow air to flow through peripheral inflatable chamber 26. Pleats 90aid in adjusting for the reduction in length of inflatable member 12upon full inflation so as to maintain a more uniform peripheral shape atregions of inflatable chamber 26 prone to buckling. It is to beappreciated that the number and size of pleats may be varied toaccommodate varying lengths and sizes of inflatable member 12.

[0042] While a novel packaging system has been described herein to becomprised of two, interconnected sections of inflatable members 12, itis intended to be understood that other packaging systems having two ormore pocket openings may be formed by interconnecting three or moresections of inflatable members 12 employing the teachings herein.Sections of inflatable members 12 may be arranged and interconnected ina manner to orient the pocket openings on a common end of the packagingsystem. Alternatively, the interconnection of sections of inflatablemembers 12 may be located to vary the orientation of each pocket openingdefined between two contiguous sections of inflatable members 12.

[0043]FIG. 12 is a partial top view of an alternative multi-cellpackaging system 100, which is formed from two film layers in a mannersimilar to system 10 of FIG. 1. As shown in FIG. 12, system 100comprises a plurality of inflatable cells 102 each of which communicateswith a common air passageway or header 104 via inlets 105. Header 104 isformed by a first edge heat seal 106 and a spaced, generally parallelheat seal 108, which interconnect the two film layers. Header 104 isopen at one end to permit the introduction of an inflation medium, suchas air. Alternatively, header 104 can communicate with a filler valve(not shown) which is similar to valve 22 of FIG. 1. The width of header104 may be varied along the length of system 100 to facilitate inflationof cells 102 downstream from the initial introduction of an inflationmedium into the header 104, in which case heat seals 106 and 108 willnot be parallel.

[0044] Inlets 105 are formed by treating sections of the inner surfacesof the two film layers where heat seal 108 is to be made with a heatresistant material, in the manner previously described. Cells 102 areformed by spaced and generally parallel heat seals 110, which extendfrom and are transverse to heat seal 108, and by a second edge heat seal112 that is generally parallel to the first edge seal 106. While onlytwo cells 102 are shown in FIG. 12, it is to be understood that system100 may comprise any desirable number of cells. Cells 102 may beinflated in a particular order, i.e., last to first, or first to last,by varying the width of inlets 105 of each cell 102. Inflation mediumwill flow through wider inlets first. Inlets 105 may vary in width by aslittle as 0.0125 inch to see this effect.

[0045] As the number of cells in system 100 increase, the ability toinflate downstream cells 102 can be significantly impacted as theinitial cells 102 inflate and shorten the length L of system 100. Thisshortening of system 100 due to inflation of cells 102 causes a strainalong seal 108, which causes a buckling or creasing of the header thatcan lead to a blockage of air flow to downstream cells. To alleviatethis buckling tendency, in one preferred embodiment, each cell 102 isformed to include a pair of heat seals 114 that extend at an anglebetween heat seals 110 and heat seal 108 adjacent to an intersection ofseals 110 and 108. As is seen in FIG. 12, seals 114, 110 and 108 isolatean area 116, which is then cut out and removed to form a void betweenadjacent cells 102 near the header 104. These cut outs relieve thestrain along seal 108 and sufficiently reduce buckling of the header toensure adequate air flow through the header to downstream cells 102 ofsystem 100.

[0046] As shown in FIG. 13, a first alternative embodiment of system 100is demonstrated that reduces the buckling effect of the header uponinflation of cells 102. According to the embodiment of FIG. 13, heatseals 110 bisect heat seal 108. Each segment of heat seal 108 is thenprovided with a slit 120, which isolates the inflation induceddimensional changes of cells 102 from header 104 and alleviates thebuckling effect along seal 108.

[0047] A second alternative embodiment of system 100 is shown in FIG.14. As shown in FIG. 14, system 100 is in a deflated state. Each heatseal 110 that separates adjacent cells 102 is provided with a centralcut 130 that extends between seal 108 and seal 112. This central cut 130permits each cell 102 to individually reduce in width W as cells 102 areinflated, such that a gap between adjacent cells 102 forms along cut130. Thus, cut 130 relieves the strain along seal 108 and preventsheader 104 from buckling.

[0048] Each cell 102 of system 100 may also incorporate a one way valve,like one way valve 32 described relative to FIGS. 1-5 a. In such anevent, individual inflated cells 102 can be severed from system 100without destroying the continuity of system 100, such as by extendingcut 130 beyond seals 106 and 112. In this manner, system 100 can have alength defined by any desirable number of cells 102 to accommodateobjects of differing sizes. System 100 can be inflated and wrappedaround an object that is to be shipped in a shipping container or box.Once inflated, additional individual cells 102 can be separated fromsystem 100 and used to fill any remaining voids in the shippingcontainer. System 100 may, for example, be formed in a roll of aplurality of cells 102. A desired number of cells 102 may be selectedand severed from the roll, resulting in a header 104 that is unsealed,as shown in FIG. 14. In such an event, the gap G between seal 106 andseal 108 at one end of the header 104 is either permanently closed witha heat seal, or temporarily closed with a clamp prior to inflation ofthe selected cells 102.

[0049]FIGS. 15 and 16 are cross-sectional views of system 100 whichincorporate a one way valve 32 previously described relative to FIGS.5-5 a. As shown in FIGS. 15 and 16, the header 104 is formed by layers15 and 17 of valve 32, which may, as shown in FIGS. 15 and 16 be acontinuous sheet of material. In FIG. 15, layers 14 and 16 are shownheat sealed to layers 15 and 17 along heat seal 108. A heat resistantmaterial, such as heat resistant material layer 140 on layer 15, isapplied at the location of inlets 105 to prevent sealing of layers 15and 17 at those locations. As shown in FIG. 16, alternatively layers 14and 16 can be sealed relative to surfaces of layers 15 and 17 adjacentto header 104. Heat resistant material layer 142 is applied to layer 15and/or 17 along header 104 to prevent sealing of layers 15 and 17 alongheader 104. The embodiment of FIG. 15 may be utilized with any of theembodiments of system 100 shown in FIGS. 12-14, while the embodiment ofFIG. 16 is particularly suited for use with the embodiment of system 100shown in FIG. 14. The embodiments of FIGS. 15 and 16 enable theformation of a header and one way valve 32 in one construction which cansubsequently be combined with a construction corresponding to inflatablecells 102 to form system 100 of any desired length.

[0050] Although the present invention has been described with referenceto preferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention. Also, various permutations of the presentinvention are possible by exchanging corresponding features of thevarious embodiments.

1. In a multi-chambered inflatable packaging system having overlyingfirst and second film layers connected together around a perimeter ofthe first and second layers by a perimeter seal except for a gapsufficient in size to allow an inflation medium to be introduced into aninterior defined between the first and second film layers, an inflationchannel formed by a first seal of the first and second film layersadjacent a portion of the perimeter, wherein the inflation channel is influid communication with the gap, a plurality of separate inflatablecells in fluid communication with the inflation channel, the pluralityof inflatable cells formed by plurality of spaced second seals extendingfrom and transverse to the first seal, the improvement comprising: meansfor maintaining airflow through the inflation channel as the pluralityof inflatable cells are inflated.
 2. The packaging system of claim 1wherein the means for maintaining airflow comprises a slit of the firstand second film layers along a portion of the first seal.
 3. Thepackaging system of claim 1 wherein the means for maintaining airflowcomprises a slit of the first and second film layers along a portion ofeach of the second seals.
 4. The packaging system of claim 3 wherein theplurality of spaced second seals extend between the first seal and afirst segment of the perimeter seal, the slit extending between thefirst seal and the first segment of the perimeter seal.
 5. The packagingsystem of claim 1 wherein the means for maintaining airflow comprises: acorner seal of the first and second film layers between the first sealand each second seal, the corner seal isolating a portion of the firstand second film layers from fluid communication with the inflationchannel and each inflatable cells, wherein the portion is thereafterremoved to create a void.